CVD nano-coating of carbon composites for space materials atomic oxygen shielding

The present work analyzes the possibility to employ carbon nanostructures as a basic material to prevent the erosion effects of atomic oxygen suffered by the carbon fiber reinforced polymeric material used in low earth orbit space environment. The application of thin protecting coatings to base materials is a widely used method for preventing the atomic oxygen induced erosion, and thus degradation. The generic purpose is to integrate carbon nanostructures onto carbon composites surface in order to develop the basic substrate of advanced nanocomposite for atomic oxygen protection. The final goal is the characterization of carbon nanostructures-reinforced carbon composites by means of on-ground atomic oxygen simulation facility, with the future objective to assess and optimize the process of carbon-multiscale advanced composites production. With such an aim, a wide investigation on the methane chemical vapor deposition (CVD) over catalyzed carbon fiber-based substrates has been carried out. The as grown nanostructures have been analyzed in terms of morphology, as well as regarding the main features of the resulting growth (yield, purity, homogeneity, coating uniformity, etc.) and the influence of the deposition route operating parameters (catalyst typology, gas flowing rate, growth time/temperature, etc.). A high degree of reproducibility in terms of the relationship between the carbon deposit type/yield and the main process variables (catalyst and protocol) has been thus obtained. Finally, atomic oxygen ground tests have been conducted in order to evaluate the coating process effectiveness. The on-ground test in atomic oxygen environment, with respect to the performances of the reference carbon composites (in terms of total mass loss and atomic oxygen rate of erosion), showed a worsening for the disordered carbon deposit, while an intriguing improvement was achieved by the high-yield carbon nano-filaments deposition.